AMG - Laser Welded Belt Case Study
Figure 1: Photo Credit LAS Ltd
Advanced Manufacturing Group (AMG) approached Laser Additive Solutions Ltd (LAS) with the process problem,
“how do we improve our production critical stainless steel belt life?”.
LAS met this challenge head on and through our expertise refined a robust, effective process to prepare, cut and laser weld belts to a high quality and consistency.
By using laser welding over conventional welding techniques, LAS has managed to improve process repeatability.
Figure 2: Photo Credit LAS Ltd
The LAS developed process is as follows:
1. Using a sophisticated roller system, each coil is unrolled and cut to desired lengths of 14.2m approx.
2. Each length is cut using a precision saw to an angle of 45°.
3. The ends of each length are prepared by removing burrs/imperfections and then placed into the high accuracy fixture (see Figure 2).
4. The ends are then laser welded together providing a highly effective joint, consequently creating a belt.
5. Upon completion of the welding, each belt is thoroughly inspected, polished and engraved to ensure high product quality and product traceability.
Figure 3: Photo Credit LAS Ltd & Walsgrave Transport
LAS Ltd use the service of Walsgrave Transport to haul the belts to Advance Manufacturing group (AMG).
The service provided is of a high quality. Belts are secured using a purpose built wooden frame structure and one standard delivery consists of 8-10 belts (see Figure 3).
Figure 4: Photo Credit AMG Aluminum UK Limited
Belts manufactured by LAS that ran to failure achieved an average of 51.32 hrs before causing a shutdown. This is almost 16hrs better than the previous best average of 35.40hrs for TiG welded belts*.
Notably since using laser welded belts AMG have substantial
savings of approx. £125,000 per year due to belt life improvements and less shutdowns*.
*Data provided by AMG Aluminum UK Limited
Figures 4 and 5
are LAS laser welded belts in action at AMG Aluminum UK Limited
Figure 5: Photo Credit AMG Aluminum UK Limited
Please see what AMG (Advanced Manufacturing Group) say about our work.
“Laser Additive Solutions have provided an exceptional service through the project we ran on improving the time-to-failure of one of our critical components.
The work done on our continuous caster belt component has increased our productivity and profitability whilst improving safety and AMG Aluminium UK’s ability to schedule material for “just in time” manufacture.
From project inception through development work to finished components and product approval, in all aspects LAS have provided 1st class technical expertise and an understanding of the need to deliver results in a timely manner."
LAS are equipped to deliver and develop consistent processes for your business, if you think we can help benefit and drive your business forward, please do not hesitate to get in touch.